Chapter 2 Value Engineering

Design Benefits

Many advantages exist in using Pultex® Profiles, compared to conventional materials, such as steel,
aluminum, wood or other plastics. Analyzing the benefits of Pultex® can mean a cost savings to you.

The first step is to compile the total cost of the application, which includes: tooling, raw materials and any
required fabrication. Costs are easily obtained from the Sales and Estimating Department of Creative
Pultrusions.

The second step is to add the cost savings that would be realized by you and the end user, in comparison
to using conventional construction materials. These savings are realized in reduced maintenance cost,
lower installation cost and reduced freight, due to lighter weight properties. Savings in the life cycle of
the product should be considered with the product’s original cost when making cost comparisons.

Light weight, high strength and electrical insulating properties make FRP profiles ideal for
third-rail coverboard on electrical mass transit systems around the world.

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 Table 2-1 Features & Benefits of Pultex® Profiles

Features Description Benefits

Strength Unit strength in tension, flexure, and • Structural design capabilities
compression is approximately 20 • Optional strength in desired directions
times that of steel when properties are • Exceptionally high impact strengths
combined on the basis of unit density
Lightweight Density of Pultex® is 20% of steel and • Higher performance at less weight
60% of aluminum • Reduced shipping costs
• Reduced operational energy demands
• Reduced labor expense for installations
• Easily handled
• Assembled and installed with ease
Corrosion Resistance Unaffected by a wide range of • Minimal maintenance costs
corrosive chemicals and environments • Long-term safety
• Installation longevity and increased service
life
• Outdoor storage capabilities
• Lower cost performance ratio
• Less need for replacements
Electrical Insulation Structural strength and rigidity are • Less components for assemblies
provided with dielectric material. • Non-magnetic
• Additional safety factors
• Predictable insulation values
Part Consolidation Many individual components can be • Reduced assembly costs
combined into one large profile. • Reduced inventory requirements
• Smooth aerodynamic surfaces
• Improved reliability
Dimensional Stability Stretch-, warp-, and swell-resistant • No permanent set under high stress
over a wide range of temperatures and • Reduced damage to structure assemblies
physical stresses. • Easy to repair misused parts
• Close tolerances
Thermal Insulation Low thermal conductivity rating of • Reduced insulation thickness requirements
1/250 of aluminum; 1/60 of steel • Reduced energy operation requirements
• No condensation problems

Applications

Construction/Industrial Bridges
Bulk head frames
Cable trays
Complete building systems
Cooling tower components
Flooring supports
Grating and supports
Pipe supports
Prefabricated walkways, platforms and handrail systems
Structural supports for process equipment
Trusses and joists
Wind blades
Window frames

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Applications (cont’d)

Automotive Automobile springs

Automotive leaf springs and bumpers
Bus components
Bus window latch supports
Dunnage bars
Roll-up doors/ insulated roll-up door panels
Spring bumpers
Tank supports
Truck/trailer wall posts

Consumer Ladders
Light poles
Mop, broom and brush handles
Pruning poles
Rake handles
Shovel handles

Wastewater Cell partitions

Scrubber components
Traveling water screens
Water/waste water treatment sludge flights

Electrical Composite utility poles

Crossarms
Crossing gate arms
Electrical enclosures
Mist eliminators
Mounting braces & backboards
Switch gear components
Third rail coverboards
Walk-in refrigeration door jambs

Marine Boat dock power posts

Fender pilings
Sheetpiles

Cost Analysis for Standard and Custom Profiles

Careful study of end-use requirements for an application will establish the potential for use of Pultex®. If
possible, designs should be drawn and the commercial feasibility determined.

The applied cost of the end uses of a pultruded profile is the sum of the tooling, raw material and
fabrication, plus the additional consideration of transportation, assembly and/or erection/installation cost.

In many cases of mechanical design or prototyping, standard Pultex® Profiles can be used. The most
economical alternative for the designer is to evaluate the material, as it may eliminate elements of cost,
such as development time, tooling, and manufacturing for limited quantity runs. Even custom profiles can
be effectively fabricated and/or assembled from available standard profiles, aiding the designer in
determining the feasibility of an idea with minimal cost.

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Tooling Costs

When the feasibility is determined and a custom profile is required, the following factors must be
considered:

1. Products selected from the list of available Pultex® standard structural profiles involve no
additional tooling cost and are normally available in any quantity through the distribution
network.

2. Tooling costs for custom pultruded profiles are dependent on the complexity of the profile and
the volume requirements, and are often less than those for traditional materials.

Raw Material Advantages

Pultex® 1500 and 1525 Series are produced with high performance grades of polyester resin,
continuous strand mat and roving. The combination provides a quality product that is economically
priced.

When the application requires higher performance ratings for standard or custom profiles, it can be
engineered with specialized reinforcements and resins.

Although premium raw materials also affect the cost of a product by adding complexity and possibly
lowering production rates, the benefits realized can usually justify the additional costs. High-
performance resins or specialized reinforcements can improve usable life or ultimate strength of a
profile.

Fabrication Advantages

Creative Pultrusions provides a full-service Fabrication Network that offers painting, punching, multi-
head drilling and assembly. If you choose to do your own fabrication, Creative Pultrusions can
provide recommendations on methods and equipment to be used based on extensive experience.
Chapter 9 provides many helpful hints in determining the optimum fabrication techniques.

Shipping Advantages

Shipping of components or sections is one segment of costs sometimes neglected in early design stages.
It particularly applies to glass-reinforced products, such as pultrusions, due to their lower density. In
most shipments, the volume of a shipping container is completely filled before the maximum shipping
weight is reached; therefore, it is important for the designer to consider this fact when designing the
profile. The ability to stack or crate the profile will affect the end-product costs.

Another consideration is length. Since pultrusion is a continuous process, it allows the designer to use
any length product possible. The only limitation is that profiles must be practical shipping lengths.
Standard shipping lengths are usually 13.1 m or less to fit the length of most common carriers.
Rods or smaller profiles, which can be coiled, have a theoretically unlimited length, although there are
some process limitations.

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